Abrasive article with a resilient dusting surface

ABSTRACT

The present invention provides an abrasive article that is capable of abrading a surface and cleaning the dust from the surface being abraded without the need for an adhesive on the cleaning surface of the abrasive article. In one embodiment, the present invention provides an abrasive article consisting essentially of a foam latex rubber layer forming a cleaning surface, a binder coated on the foam latex rubber layer, and abrasive particles attached to the binder forming an abrasive surface.

BACKGROUND

The present invention relates to abrasive articles, and moreparticularly, to a hand-held, abrasive article that includes a resilientdusting or cleaning surface.

Common sanding tasks calling for considerable detail work or access tosmall confined areas, or for sanding contoured surfaces, often requirethat the surfaces be hand sanded. Hand-held sanding devices for thispurpose have essentially consisted of a sanding block for holdingconventional sandpaper wrapped over the block. By using a sanding blockas a sandpaper holder, hand-applied sanding forces on the sandpaper canbe increased and more evenly distributed.

The difficulty with the above-mentioned prior sanding devices is thenecessity of installing or wrapping a separate piece of sandpaper aroundthe device. This installation or wrapping process presents someinconvenience to the user. For example, if the paper is improperlyinstalled, it is susceptible to buckling or falling off. Also, thedevice requires the purchase of separate sheets of sandpaper that is afurther inconvenience in terms of the amount of supplies needed.

U.S. Pat. No. 4,887,396 (Lukianoff) discloses a hand-sized sandingdevice that eliminates the need for a separate sheet of sandpaper. Thesanding device is provided with its own integral abrasive surfaces thatcan be manufactured at a sufficiently low cost to be disposable. Thesanding device of Lukianoff can be conveniently used to hand sand avariety of standard, contoured, or shaped surfaces, such as trim ormolding surfaces, and for projecting into exactly defined areas.

Another type of sanding device is the resilient flexible sanding sponge.Sanding sponges generally include a layer of abrasive particles adheredto a foam body by a flexible adhesive. The flexible adhesive layer andthe foam body permit the layer of abrasive to conform to the surfacebeing abraded.

When sanding surfaces such as wood, plaster, or drywall, small particlesof dust are released into the air and surrounding surfaces. Theseparticles often settle over the surface being sanded. A user willtypically clean the surface being sanded to assess the quality of thesanding and to determine if more sanding is necessary. To clean thesurface, the user must use a separate cleaning tool, such as a dustingcloth or tack cloth, to clean the surface being sanded. It may be timeconsuming to locate and use a separate cleaning tool. Additionally,dusting cloths often become loaded with the dust and simply push thedust and do not effectively pick up the dust. Tack cloths are oftencoated with an adhesive to help pick up the dust and retain it in thecloth. However, the user risks transferring adhesive to the surfacebeing cleaned with the cloth. The transferred adhesive can prevent aquality application of stain, varnish, or sealant to the surface beingsanded.

SUMMARY

The present invention provides an abrasive article that is capable ofabrading a surface and cleaning the dust from the surface being abradedwithout the need for an adhesive on the cleaning surface of the abrasivearticle. In one embodiment, the present invention provides an abrasivearticle consisting essentially of a foam latex rubber layer forming acleaning surface, a binder coated on the foam latex rubber layer, andabrasive particles attached to the binder forming an abrasive surface.

In another embodiment, the present invention provides an abrasivearticle comprising an abrasive layer on an intermediate support layerforming an abrasive surface and a foam latex rubber layer attached tothe intermediate support layer, opposite the abrasive layer, and forminga cleaning surface. The intermediate support layer is selected from thegroup consisting of a paper, a file, and a nonwoven of lofty web offibers.

In another embodiment, the present invention provides an abrasivearticle comprising an abrasive layer comprising a lofty web of fibersforming an abrasive surface and a foam latex rubber layer laminated tothe abrasive layer, opposite the abrasive surface, and forming acleaning surface. The cleaning surface is essentially free of adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of an abrasivearticle according to the present invention.

FIG. 2 is a perspective view of a second embodiment of an abrasivearticle according to the present invention.

FIG. 3 is a perspective view of a third embodiment of an abrasivearticle according to the present invention.

While the above-identified drawings and figures set forth one embodimentof the invention, other embodiments are also contemplated, as noted inthe discussion. In all cases, this disclosure presents the invention byway of representation and not limitation. It should be understood thatnumerous other modifications and embodiments can be devised by thoseskilled in the art, which fall within the scope and spirit of thisinvention. The figures may not be drawn to scale. Like referencenumbers, incremented by 100, have been used to denote like parts.

DETAILED DESCRIPTION

FIG. 1 shows a flexible resilient abrasive article 100 comprising anabrasive layer 110 and a foam latex rubber layer 130. The abrasive layer110 comprises a plurality of abrasive particles 112 at least partiallyembedded in a binder layer 114. In this embodiment, the binder layer 114is directly on the foam latex rubber layer 130. The resulting abrasivearticle 100 comprises at least one abrasive surface 160 and at least onecleaning surface 170.

FIG. 2 shows a flexible resilient abrasive article 200 comprising anabrasive layer 210 and a foam latex rubber layer 230. The abrasive layer210 comprises a nonwoven. Such a nonwoven is a Scotch-Brite™ ScouringPad available from 3M Company of St. Paul, Minn. The abrasive layer 210is attached to the foam latex rubber 230 through any known variety ofattachments techniques such as adhesives or laminating. The resultingabrasive article 200 comprises at least one abrasive surface 260 and atleast one cleaning surface 270.

FIG. 3 shows a flexible resilient abrasive article 300 comprising anabrasive layer 310 and a foam latex rubber layer 330. The abrasive layer310 comprises an intermediate support layer 320 and a plurality ofabrasive particles 312 at least partially embedded in a binder layer 314on the intermediate support layer 320. The intermediate support layer320 of the abrasive layer 310 is attached to the foam latex rubber 330through any known variety of attachment techniques such as adhesives orlaminating. The resulting abrasive article 300 comprises at least oneabrasive surface 360 and at least one cleaning surface 370.

In each of the embodiments of the abrasive article described in FIGS.1-3 the resulting abrasive article includes an abrasive layer and a foamlatex rubber layer. The abrasive layer provides the abrasive surfacethat is capable of sanding such surfaces as wood, plaster, drywall, orother similar surfaces. The foam latex rubber layer provides thecleaning surface that is capable of removing small particles, such as,dust before or after the abrasive surface is used to abrade or scour thesurface.

The abrasive layer, foam latex rubber layer, and attaching layer (ifincluded in the embodiment) are each discussed in further detail below.

Abrasive Layer

The abrasive layer may comprise any known abrasive such as but notlimited to abrasive particles embedded in a binder or nonwovenmaterials. Optionally, an intermediate layer may be provided. Theintermediate layer may be, for example, a paper, a nonwoven, a foam,film or a sponge that is directly attached to the foam latex rubberlayer.

If abrasive particles and a binder are used, the binder may be directlycoated on the foam latex rubber, as depicted in FIG. 1, or anintermediate layer may be included. Therefore, either the foam latexrubber or the intermediate layer may be coated with the binder andabrasive particles. In one embodiment, the binder is a flexible adhesivethat bonds the layer of abrasive particles to either the foam latexrubber layer or the intermediate layer. The binder adheres the abrasiveparticles together while being sufficiently flexible to conform to theflexible surface of the foam latex rubber or the intermediate support. Aflexible adhesive formulation and method of applying it is described inU.S. Pat. No. 6,059,850, herein incorporated by reference, which can beused to form the binder. Other suitable binders include any of thethermosetting or photocurable resins including phenol-formaldehyde,urea-formaldehyde and melamine-formaldehyde resins, epoxy resins,acrylate resins, aminoplast resins and urethane resins, includingmixtures and/or modified versions thereof. The binder may be coatedusing conventional techniques, such as knife coating, spray coating,roll coating, rotogravure coating, curtain coating, and the like.

In some embodiments a pre-make coat resin layer may be used to seal thesurface of the foam latex rubber layer or intermediate layer, ifincluded. Suitable pre-make coat resins may be applied as solvent orwater based formulations or as 100% solids hot melt formulations.Additionally, in some embodiments, the abrasive article may also includean optional size coat extending over the binder and the abrasiveparticles. Suitable size resins include those mentioned for pre-makecoat resins.

In general, any suitable abrasive particles may be used with thisinvention. Suitable abrasive particles include fused aluminum oxide,heat treated aluminum oxide, alumina-based ceramics, silicon carbide,zirconia, alumina-zirconia, garnet, diamond, ceria, cubic boron nitride,ground glass, quartz, titanium diboride, sol gel abrasives andcombinations thereof. The abrasive particles can be either shaped (e.g.,rod, triangle, or pyramid) or unshaped (i.e., irregular). The term“abrasive particle” encompasses abrasive grains, agglomerates, ormulti-grain abrasive granules. The abrasive particles can be depositedonto the binder layer by any conventional technique such aselectrostatic coating or drop coating.

If included, the intermediate support layer is attached to the foamlatex rubber and includes the abrasive surface, which typically willinclude a coating of the binder and abrasive particles. In one preferredembodiment, the intermediate support layer is resiliently deformable(i.e., indentable) and recoverable when squeezed by the thumb andfingers of the user's hand and thus is not likely to slip from the handeven if the fingers are wet or greasy. The intermediate support layermay be somewhat resiliently axially compressible and acts as a cushionbetween the user's hand and the work surface as the abrasive article isbeing pushed back and forth to perform the abrading function.

The intermediate support layer may be open cell foam, closed cell foam,textured, or planar, natural or synthetic sponge, nonwoven, paper, orfilm. In one embodiment, the intermediate support layer is closed-cellfoam. In some embodiments, the intermediate support layer may beconstructed from high tear strength felted urethane foam.

Abrasive particles along with a binder are not required for the abrasivelayer. Another suitable abrasive layer may be a nonwoven. Such anonwoven may comprise, for example, an open, lofty nonwoven web offibers bonded at their points of contact by a resin and/or melt fusion.The nonwoven may also include abrasive particles dispersed throughoutthe nonwoven or coated on a surface of the nonwoven and secured to thenonwoven web by a binder.

Suitable fibers include crimped, staple, synthetic organic fibers suchas polyester fibers and nylon fibers, which may be processed andentangled into nonwoven webs by conventional web-forming machines suchas that sold under the tradename “Rando Webber” through Rando MachineCompany of New York, N.Y. The resulting web may be heated to bring aboutmelt-bonding of the fibers at their points of contact, and/or may betreated (by spraying, roll-coating, etc.) with a liquid resin whichbonds the fibers together.

Suitable nonwovens, which may serve as the abrasive layer, are availablecommercially in a variety of thicknesses, densities and abrasive powersunder the tradename Scotch-Brite™ from 3M Company of St. Paul, Minn.

Foam Latex Rubber

The foam latex rubber layer provides the cleaning surface. Particularly,the foam latex rubber is effective at removing dust and other smallparticles from work surface. In one embodiment, the foam latex rubber isan open-cell foam. The open cell-foam provides small pockets that arecapable of capturing and retaining the dust and other small particlesthat are encountered during cleaning before and after sanding. A foamedlatex rubber suitable for the foam latex rubber layer is sold under thetradename Gonzo available from Quality Rubber Company, a division ofZephyr Manufacturing of Sedalia, Mo.

The latex rubber material is a natural material that exhibits a naturaltackiness without the need for the addition of a secondary adhesive.This natural tackiness is unique and advantageous in use as a cleaningand dusting material. The tackiness assists in picking up and retainingdust and small particles. Because a secondary adhesive is not required,the risk of adhesive transfer to the surface being cleaned iseliminated. To increase the tackiness of the abrasive article, in oneembodiment, an additional adhesive may be included for someapplications. Additionally, the latex rubber material may be cleanedusing water or other solvents and following cleaning retains a naturaltackiness.

Attaching Layer

If included, the attaching layer secures the abrasive layer to the foamlatex rubber. As shown in FIGS. 2 and 3 an attaching layer is used tosecure the abrasive layer to the foam latex rubber and the intermediatelayer of the abrasive layer to the foam latex rubber, respectively.

The attaching layer typically is an adhesive. Suitable adhesives includepressure-sensitive adhesives, hot melt adhesives, or thermosettingadhesives. In one embodiment, laminating, using heat and pressure, isused to secure these layers together.

Abrasive Article

The abrasive articles depicted in FIGS. 1-3 are generally rectangularwith a substantially planar abrasive surface and a substantially planarcleaning surface that is opposite the abrasive surface. The abrasivearticle may be square or rectangular and is of a suitable size forhandheld sanding. For example, the abrasive article may have a lengthfrom 3 to 6 inches (7.62 to 15.24 cm), a width from 1 to 6 inches (2.54to 15.24 cm) and a thickness from 0.5 to 4 inches (1.27 to 10.16 cm).The abrasive article may be any convenient geometric shape other thansquare or rectangular including, but not limited to, triangular,circular, and in the shape of a polygon. Additionally, the abrasivearticle need not be a defined shape but could be randomly shaped such asa wave shape.

As shown in the embodiment depicted in the figures, the abrasive articleincludes a single abrasive surface and a single cleaning surface. Asshown in these embodiments, the abrasive surface and the cleaningsurface are generally planar and parallel to one another. The presentinvention is not limited to a single abrasive and a single cleaningsurface. The abrasive article may be of a shape or configuration havingtwo or more abrasive surfaces and/or having two or more cleaningsurfaces. Additionally, the abrasive surface and cleaning surface neednot be planar and may be of other geometric or curved shapes. Otherembodiments and configurations of the abrasive surface and cleaningsurface are within the scope of the present invention, so long as thereis at least one abrasive surface and one cleaning surface.

To enhance the durability of the abrasive article, an embeddedreinforcing scrim may be included. The scrim may be positioned betweenthe foam latex rubber and the abrasive layer or may be imbedded withinan intermediate layer, if included.

The abrasive article can be used in a variety of cleaning, sanding, andsurface conditioning processes. A particularly useful area for theabrasive article is in the preparation of surfaces, especially wood,plaster, and drywall, and for painting or finishing.

To use the abrasive article, the user can grasp the abrasive article byhand with the cleaning surface of the foam latex rubber facing the palmof the user's hand. Then, the abrasive surface of the abrasive layer isavailable for contact with a surface. The user sands the surface withthe abrasive layer and, following sanding, uses the cleaning surface ofthe foam latex rubber to wipe the dust and debris from the surface beingsanded and any surrounding surfaces. Once the foam latex rubber is fullyloaded with dust and debris from cleaning, the user can rinse the foamlatex rubber with water to remove the dust and debris. When the foamlatex rubber layer is cleaned, the abrasive article is available forfurther use.

1. An abrasive article consisting essentially of: a porous foam latexrubber layer forming a porous cleaning surface; a binder coated on thefoam latex rubber layer; and abrasive particles attached to the binderforming an abrasive surface.
 2. The abrasive article of claim 1, whereinthe abrasive surface is substantially planar and the cleaning surface issubstantially planar.
 3. The abrasive article of claim 2, wherein theabrasive surface is opposite the cleaning surface.
 4. The abrasivearticle of claim 1, wherein the cleaning surface is essentially free ofadhesive.
 5. An abrasive article comprising: an abrasive layer on anintermediate support layer forming an abrasive surface; a porous foamlatex rubber layer attached to the intermediate support layer, oppositethe abrasive layer, and forming a porous cleaning surface; wherein theintermediate support layer is selected from the group consisting of apaper, a film, and a lofty web of fibers.
 6. The abrasive article ofclaim 5, wherein the abrasive layer comprises: abrasive particlesattached to the intermediate support layer with a binder.
 7. Theabrasive article of claim 5, wherein the abrasive surface issubstantially planar and the cleaning surface is substantially planar.8. The abrasive article of claim 7, wherein the abrasive surface isopposite the cleaning surface.
 9. The abrasive article of claim 5,wherein the cleaning surface is essentially free of adhesive.
 10. Anabrasive article comprising: an abrasive layer comprising a lofty web offibers forming an abrasive surface; a porous foam latex rubber layerlaminated to the abrasive layer, opposite the abrasive surface, andforming a porous cleaning surface; wherein the cleaning surface isessentially free of adhesive.